N10801

Part: SLIDE — DEPLOYED (L2 DOOR) · airframe 3,268,059 hrs

THE L2 DOOR WAS PARTIALLY OPEN WHEN A GUST OF WIND FORCED THE DOOR TO THE FULL OPEN POSITION CAUSING THE SLIDE BOTTLE TO DEFLATE AND PARTIALLY DEPLOY THE SLIDE.

Part: BATTERY — INOPERATIVE (EMERGENCY LIGHT) · airframe 47,778 hrs · 35,719 cycles

AIRCRAFT IN MAINTENANCE, SYR. CENTER ISLE EMERGENCY LIGHTS INOPERATIVE.REMOVED AND REPLACED BATTERIES AT CENTER ISLE LIGHT POWER SUPPLY IAW MM.

Part: LIGHT — INOPERATIVE (EMERGENCY EXIT)

AIRCRAFT IN MAINTENANCE SYR. LT FWD ENTRY EMERGENCY EXIT LIGHT INOPERATIVE.REMOVED AND REPLACED FORWARD ENTRY EMERGENCY EXIT LIGHT ASSEMBLY IAW MM.

Part: TAIL CONE — DEPLOYED · airframe 47,683 hrs · 35,673 cycles

AIRCRAFT IN MAINTENANCE-TOL. TAIL CONE WAS INADVERTENTLY DEPLOYED BY RAMP SERVICE PERSONNEL. REINSTALLED TAIL CONE IAW MM 535300. SFB MAINTENANCE ENTRY 8/27/2004. INSPECT TAIL CONE EVACUATION SLIDE FOR PROPER INSTALLATION. INSPECTED SLIDE IAW MM 256200. NO DEFECTS NOTED.

Part: INDICATOR — INOPERATIVE (MLG)

ON APPROACH IN TO RFD. RT MAIN GEAR LIGHT ASSY, INOPERATIVE. ALL GEAR INDICATIONS INOPERATIVE ON RT GEAR. EMERGENCY DECLARED. AIRCRAFT LANDED WITHOUT INCIDENT. REPAIRED LANDING GEAR INDICATION PANEL ASSY, ALL GEAR INDICATIONS GOOD. LANDING GEAR POSITION INDICATOR SUBSEQUENTLY REPLACED ON JULY 06 2004 BY TOL MTX.

Part: BATTERY — DISCHARGED (FLASHLIGHT) · airframe 45,361 hrs · 34,231 cycles

INSPECTION FOUND THE FORWARD ENTRY I/B EMERGENCY FLASHLIGHT INOPERATIVE. THE FLASHLIGHT BATTERY WAS REPLACED.

Part: BATTERY PACK — INOPERATIVE (ROWS 9-12) · airframe 45,361 hrs · 34,231 cycles

THE OVERHEAD EMERGENCY LIGHTS AT ROWS 9-12 WERE FOUND INOPERATIVE. THE BATTERY PACK WAS REPLACED AND OPERATIONAL CHECKS WERE GOOD IAW MM 33-53-00.

Part: BATTERY PACK — INOPERATIVE (EXIT SIGN) · airframe 45,361 hrs · 34,231 cycles

THE FORWARD OVERWING EMERGENCY EXIT DOOR SIGN FAILED DURATION TEST. THE BATTERY PACK WAS REPLACED AND OPERATIONAL CHECKS WERE GOOD IAW MM 33-53-00.

Part: FUSE — INOPERATIVE (BATTERY PACK) · airframe 45,361 hrs · 34,231 cycles

THIRTEEN AFT SEAT MOUNTED EMERGENCY PATH LIGHTS WOULD NOT ILLUMINATE WHEN TESTED. THE AFT BATTERY PACK FUSE WAS REPLACED AND OPERATIONAL CHECKS WERE GOOD.

Part: BATTERY PACK — INOPERATIVE (ROWS 19-23) · airframe 45,361 hrs · 34,231 cycles

THE OVERHEAD EMERGENCY EXIT LIGHTS AT ROWS 19-23 FAILED DURATION TEST. THE BATTERY PACK WAS REMOVED AND REPLACED AND OPERATIONAL CHECKS WERE GOOD IAW MM 33-53-00.

Part: SKIN — CRACKED (FUSELAGE) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND SKIN CRACKED IN TWO PLACES AT STA 1485 JUST FORWARD OF RUDDER TRIM ACTUATOR, RT SIDE. THE CRACKS WERE 1 INCH LONG. THE CRACKED AREAS WERE ROUTED AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-01, FIGURE 1, 52-01, FIGURE 1, AND 51-30-2.

Part: WEB — CORRODED (FUSELAGE) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND FORWARD CARGO AREA CUSP WEB CORRODED AT FS 237, L18R, FORWARD AND AFT OF FLOORBEAM JOIST FITTING. THE CORRODED SECTION OF CUSP WEB WAS REMOVED AND A NEW CUSP WEB REPAIR DOUBLER WAS INSTALLED IAW 53-01, FIGURE 2, 51-30-2, 51-30-5, AND 51-30-1.

Part: SKIN — CRACKED (FUSELAGE) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND SKIN CRACKED AT AFT SIDE OF CANTED FRAME STA 1485, LT SIDE. THE CRACK WAS STOP DRILLED AND A DOUBLER WAS INSTALLED IAW SRM 51-10-4, 53-01, FIGURE 3, 51-30-2, AND MM 20-10-17.

Part: TORQUE BOX — PUNCTURED (AFT CARGO BAY) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND TORQUE BOX WEB PUNCTURED AROUND NUT PLATES UPON REMOVAL OF AFT CARGO TIEDOWN TRACK. THE WEB SECTION WAS REMOVED AND REPLACED IAW ECRA 5310-04106 AND EA 9-5310-2-A0853.

Part: DOOR FRAME — CORRODED (FWD CARGO BAY) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND FORWARD CARGO DOOR JAMB PAN CORRODED AROUND RIVET NUTS. THE LOWER DOOR JAMB PAN WAS REMOVED AND A NEW SECTION WAS INSTALLED USING SPLICES IAW SRM 53-05, FIGURE 44 AND 51-30-01.

Part: FRAME — CRACKED (FUSELAGE) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND A 5 INCH CRACK IN AFT FACE OF FRAME AT LT SIDE, STA 1380, AT ANTI-ICING VALVE. THE CRACKED AREA WAS ROUTED OUT AND A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-01, FIGURE 1 & FIGURE 2, 51-10-3, 51-10-8, AND 51-30-2.

Part: FLOORBOARD — TORN (CABIN) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND MAIN CABIN O/B FLOORBOARD TORN AT FS 140 - 200. THE FLOORBOARD WAS REMOVED AND A NEW FLOORBOARD WAS INSTALLED IAW ECRA 5100-01844.

Part: WEB — CORRODED (FWD CARGO BAY) · airframe 43,831 hrs · 33,322 cycles

INSPECTION FOUND FORWARD CARGO DOOR JAMB OPENING AFT TORQUE BOX WEB CORRODED AT FS 430. THE CORRODED AREA WAS CUT OUT, A FILLER AND DOUBLER REPAIR WAS INSTALLED IAW EA 9-5310-2-A0851.

Part: SKIN — DELAMINATED (RT SPOILER) · airframe 43,400 hrs · 33,062 cycles

INSPECTION FOUND O/B FLIGHT SPOILER ON RT WING DELAMINATED ON TOP SURFACE AFT OF CENTER HINGE POINT. THE RT O/B SPOILER PANEL WAS REMOVED AND REPLACED IAW MM 27-61-01.

Part: CABLE — FRAYED (TAIL CONE)

THE TAIL CONE DID NOT COMPLETELY RELEASE FROM AIRCRAFT WHEN OPERATED FROM AFT VENTRAL DOOR. THE FRAYED CABLE WAS REPLACED AND RIGGED IAW MM 53-53-0.

Part: SKIN — GOUGED (BS232)

THE JETWAY LEFT A GOUGE IN LT FUSELAGE SKIN AT STA 232, LONGERON 7L. REPAIRED IAW ECRA 5330-02742.

Part: SKIN — DENTED (BS 237-249)

INSPECTION FOUND DENTS IN FUSELAGE SKIN FROM STA 237 TO 249 BETWEEN LONGERONS 16L AND 17L AND. ALSO, THE SKIN WAS BULGING AROUND FASTENERS AT STA 237 TO 269, LONGERONS 17L AND 18L. A FLUSH REPAIR WAS ACCOMPLISHED AT THE DENTED AREA IAW ECRA 5330-02445. THE LONGERONS WERE REPAIRED IAW SRM 53-02.

Part: SEAT TRACK — CORRODED (BS 1098-1193)

INSPECTION FOUND LT INBOARD SEAT TRACK CORRODED AT CLIP NUT, STA 1098-1193. THE SEAT TRACK WAS REMOVED AND REPLACED IAW SRM 53-05, FIGURE 4F, PAGE 10Q.

Part: FLOORBEAM — CORRODED (BS 218)

INSPECTION FOUND CORROSION UNDER NUT PLATE ON FLOORBEAM AT STA 218 LBL 54, UNDER FORWARD LAV FLOOR PANEL. A REPAIR DOUBLER WAS INSTALLED IAW SRM 53-05, FIGURE 20A.

Part: SUPPORT — CRACKED (BS 927)

INSPECTION FOUND A .5 INCH CRACK IN RT CABIN FLOOR SUPPORT AT BELTFRAME STA 927. THE FLOOR SUPPORT WAS REMOVED, A NEW FLOOR SUPPORT WAS INSTALLED IAW SRM 51-30-5.

Part: BULKHEAD WEB — CRACKED (BS 1463)

INSPECTION FOUND A 6 INCH CRACK IN WEB SECTION AT TAIL COMPARTMENT CANTED BULKHEAD STA 1463. THE WEB SECTION WAS REMOVED AND REPLACED IAW SRM 51-30-2.

Part: SEAT TRACK — CORRODED (BS 230)

INSPECTION FOUND SEAT TRACK CORRODED AT STA 230. THE SEAT TRACK WAS REPLACED IAW SRM 53-05, FIGURE 4F.

Part: SKIN — DENTED (BS 226)

INSPECTION FOUND FUSELAGE SKIN DENTED AT STA 226, LONGERON 17L. REPAIRED IAW SRM 53-04, FIGURE 47.

Part: SEAT TRACK — CORRODED (BS 200-240)

INSPECTION FOUND RT CENTER SEAT TRACK CORRODED AT STA 200 TO 240. THE SEAT TRACK WAS REPLACED IAW SRM 53-05, FIGURE 4F.

Part: C-4 BLADE — BROKEN (NR 1 ENGINE)

THE NR 1 ENGINE GAVE OFF A LOUD BANG WITH VIBRATION AND YAW FELT WHILE EN ROUTE. THE NR 1 ENGINE GAUGES BECAME ERRATIC. THE N1 AND N2 EVENTUALLY STABILIZED. THE AIRCRAFT WAS DIVERTED TO MSY WHERE IT LANDED WITHOUT INCIDENT. THE NR 1 ENGINE WAS REMOVED AND REPLACED. *S/D* INVESTIGATION CONCLUDED THAT THE PRIMARY CAUSE OF ENGINE FAILURE WAS DUE TO A BROKEN C-4 BLADE.

Part: ANGLE — CRACKED (NR 2 LE SLAT)

INSPECTION FOUND A 1.25 INCH CRACK IN LT WING LEADING EDGE RIB LOWER ATTACH ANGLE JUST OUTBOARD OF NR 2 SLAT TRACK. A NEW ANGLE WAS FABRICATED AND INSTALLED IAW SRM 51-30-5.

Part: SKIN — CRACKED (RT WING LE)

INSPECTION FOUND A 3.5 INCH CRACK IN RT WING LOWER LEADING EDGE SKIN JUST OUTBOARD OF NR 7 SLAT TRACK. THE SKIN WAS REPAIRED IAW ECRA 5730-01468.

Part: CLIPS — OUT OF ADJUST (TAILCONE)

THE TAILCONE INTERIOR AND EXTERIOR RELEASE HANDLE PULL FROM CLIPS WAS LESS THAN 25 POUNDS AND LESS THAN 10 POUNDS, RESPECTIVELY. THE HANDLE RETAINER CLIPS WERE ADJUSTED IAW MM 53-53-00.

Part: CABLES — OUT OF ADJUST (TAILCONE)

THE TAILCONE RELEASE HANDLE PULL WAS HIGH AT BOTH THE INTERIOR AND EXTERIOR HANDLES AND THE TAILCONE FAILED TO DROP FROM AIRCRAFT. THE TAILCONE RELEASE SYSTEM CABLES WERE ADJUSTED IAW MM 53-53-00, PAGE 501.

Part: OVEN — DIRTY (AFT GALLEY)

THE AFT GALLEY OVEN BEGAN TO SMOKE WHILE AT CRUISE PORTION OF FLIGHT. THE AFT HALON FIRE EXTINGUISHER WAS USED IN AFT GALLEY OVEN AND THE SMOKE CEASED. BURNED PAPER PRODUCTS WERE FOUND INSIDE OVEN. MAINTENANCE FOUND NO DAMAGE TO OVEN AND NO DEFECTS WERE FOUND. THE OVEN WAS CLEANED AND A NEW FIRE EXTINGUISHER WAS INSTALLED.

Part: STRUT — OVERSERVICED (NLG)

THE NOSE GEAR WOULD NOT RETRACT AFTER TAKEOFF. THE GEAR WAS RECYCLED WITH UNSUCCESSFUL RESULTS. THE AIRCRAFT WAS RETURNED TO IAH WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE NOSE STRUT OVERSERVICED. THE STRUT WAS SERVICED PROPERLY WITH NITROGEN AND A GEAR SWING WAS GOOD. A DIP WAS ISSUED REQUIRING FULL NOSE STRUT SERVICE PER MM 32-21-02, AT THE NEXT MAINTENANCE RUN WITH CAPABILITIES.

Part: T4 BLADE — BROKEN (NR 1 ENGINE)

THE NR 1 ENGINE FAILED WHILE EN ROUTE. THE AIRCRAFT WAS RETURNED TO LAS WHERE IT LANDED WITHOUT INCIDENT. THE AIRCRAFT WAS TAKEN OUT OF SERVICE FOR ENGINE REPLACEMENT. THE SDR WILL REMAIN OPEN FOR PART INFORMATION PENDING INVESTIGATION. *S/D* SHOP FINDINGS REVEALED A BROKEN T-4 BLADE.

Part: BALLAST — OVERHEATED (CABIN)

CREW CALLED MAINTENANCE WHILE AIRCRAFT WAS AT GATE, STATING THEY SMELLED SMOKE IN THE CABIN. MAINTENANCE FOUND THAT A LIGHT BALLAST ABOVE ROW 19 DEF HAD GOTTEN HOT AND SCORCHED THE OVERHEAD BIN. ALSO, THE PSU CENTER LIGHTING CIRCUIT BREAKER IN THE COCKPIT WAS FOUND POPPED. MAINTENANCE FOUND THAT A WIRE RUNNING ABOVE THE SAME OVERHEAD BIN HAD GROUNDED. THE BALLAST WAS REPLACED. ALSO, THE ADJACENT BALLAST WAS REPLACED AS A PRECAUTIONARY MEASURE. THE OVERHEAD BIN WAS PULLED DOWN AND THE CHARRED WIRING WAS REPLACED AND THE INSULATION WAS REPAIRED.

Part: BATTERY PACK — DISCHARGED (CABIN)

INSPECTION FOUND EXTERIOR EMERGENCY EXIT LIGHTS INOPERATIVE. THE BATTERY PACK AND LIGHT SOCKET WERE REMOVED AND REPLACED.

Part: CONNECTOR — CONTAMINATED (APU)

EWR - FLT 0305 - WHILE APU WAS POWERING THE LT BUS, WITH LT GENERATOR PLACARDED INOPERATIVE & THE RT GENERATOR COVERING RT BUS, BOTH GENERATORS DROPPED OFF LINE ON TAKEOFF FROM EWR. THE LOSS OF GENERATOR WAS ACCOMPANIED BY ILLUMINATION OF THE APU GENERATOR FEEDER FAULT LIGHT. POWER COULD NOT BE RESTORED. AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED SAFELY ON EMERGENCY POWER. MX FOUND OIL IN THE APU FEEDER CABLE FIREWALL DISCONNECT PLUG P1-1110. PLUG WAS REMOVED AND CLEANED. APU GENERATOR WAS POWERED AND ALL CHECKED GOOD. LT GENERATOR PLACARD WAS CLEARED BY REPLACING LT ENGINE RELAY. ALL ENGINES WERE RUN & OPERATION OF ALL GENERATORS CHKED GOOD. SUPPLEMENT - INSP BY MX FND NO SOURCE OF OIL LEAKAGE.(X)

Part: PANEL — INOPERATIVE (GEN CONTROL)

FLT NR 0679 - EWR - WHILE OPERATING THE APU, WITH THE NR 1 GENERATOR PLACARDED INOPERATIVE. THE APU GENERATOR FEEDER FAULT LIGHT ILLUMINATED. THE AIRCRAFT WAS RETURNED TO EWR WHERE IT LANDED WITHOUT INCIDENT. MAINTENANCE FOUND THE APU GENERATOR CONTROL UNIT AT FAULT. THE APU GENERATOR CONTROL UNIT WAS REMOVED AND REPLACED. (W)